Simultaneous production of high density carbon foam sections

Abstract

The present invention includes methods for simultaneously producing, within a single container, two or more sections of high density carbon foam materials of defined shape. A method used to prepare high density carbon foam sections may involve heating a comminuted agglomerating bituminous coal bed, that is at least partially divided into two or more sections by the use of partitions within the coal bed, to an elevated temperature sufficient to result in the coal particles softening and melting together to form sections of a generally homogeneous, continuous, open cell carbon material. The sections of homogeneous open cell carbon material are then maintained at an elevated temperature for a period of time sufficient to substantially reduce or essentially eliminate the plastic properties of the bituminous coal. As desired, the resultant high density carbon foam sections may be cooled to essentially ambient temperatures or immediately or subsequently heated to elevated temperatures as great as about 3200° C., followed by cooling.

1. A method for producing at least two sections of high density carbon foam within a single container, the method comprising the steps of:
 dividing a coal bed into at least two coal bed sections in a container, wherein the coal bed comprises comminuted agglomerating bituminous coal; 
 simultaneously heating the at least two coal bed sections to a first elevated temperature, wherein the first elevated temperature is sufficient to convert said at least two coal bed sections into at least two substantially homogeneous, non-sintered, open cell carbon materials; and 
 continued heating of the at least two substantially homogeneous, non-sintered, open cell carbon materials at an elevated temperature for a time sufficient to essentially eliminate the plastic properties of the at least two substantially homogeneous, non-sintered, open cell carbon materials to provide at least two sections of high density carbon foam. 
 
     
     
       2. The method of  claim 1 , further comprising the step of heating said high density carbon foam to a second elevated temperature greater than about 700° C. 
     
     
       3. The method of  claim 2 , wherein said second elevated temperature is greater than about 950° C. 
     
     
       4. The method of  claim 1 , wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere. 
     
     
       5. The method of  claim 2 , wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere. 
     
     
       6. The method of  claim 3 , wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere. 
     
     
       7. The method of  claim 1 , further comprising the step of cooling said high density carbon foam to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere. 
     
     
       8. The method of  claim 2 , further comprising the step of cooling said high density carbon foam to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere. 
     
     
       9. The method of  claim 3 , further comprising the step of cooling said high density carbon foam from said to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere. 
     
     
       10. The method of  claim 1 , further comprising the step of compacting at least one coal bed section. 
     
     
       11. The method of  claim 1 , further comprising the step of covering the container with a lid prior to heating said at least two coal bed sections. 
     
     
       12. The method of  claim 1 , further comprising the step of placing a bottom surface covering in said container prior to introduction of said comminuted agglomerating bituminous coal. 
     
     
       13. The method of  claim 1 , further comprising the step of covering a least a portion of one coal bed top surface with a coal bed covering. 
     
     
       14. The method of  claim 13 , further comprising the step of covering a least a portion of a coal bed covering with a rigid sheet material. 
     
     
       15. The method of  claim 1 , further comprising the step of covering a least a portion of at least one of a coal bed top surface with a rigid sheet material. 
     
     
       16. The method of  claim 1 , further comprising the step of compacting at least a portion of at least one coal bed section, wherein said compacting of at least a portion of at least one coal bed section is performed prior to introduction of the coal into the container. 
     
     
       17. The method of  claim 1 , wherein said atmosphere has a pressure between about 0 psig and 500 psig. 
     
     
       18. The method of  claim 7 , further comprising the step of heating said high density carbon foam to a second elevated temperature greater than about 700° C. after said cooling. 
     
     
       19. The method of  claim 18 , wherein said second elevated temperature is greater than about 950° C. 
     
     
       20. The method of  claim 18 , wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere. 
     
     
       21. The method of  claim 19 , wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.